Solenoid terminal assembly

ABSTRACT

A terminal assembly for a tubular solenoid including a terminal cap having a pair of terminals secured thereto with openings therethrough which receive leads from the solenoid coil and may be attached to the terminals. An insulator is provided to coact with metal parts of the solenoid to enable the coil leads to be completely insulated therefrom.

United States Patent Inventor Robert W. Flentge Roselle, Ill.

Appl. No. 36,564

Filed May 12,1970

Patented Sept. 28, 1971 Assignee Dormeyer Industries, Inc.

Chicago, Ill.

SOLENOID TERMINAL ASSEMBLY 14 Claims, 8 Drawing Figs.

U.S. Cl 335/278, 335/202, 335/255, 336/192 Int. Cl H011 7/00, 110111 45/02, l-lOlh 45/04 Field of Search 335/278,

[56] References Cited UNITED STATES PATENTS 3,028,570 3/1962 Taylor 336/192 X FOREIGN PATENTS 1,184,185 7/1967 Great Britain.... 336/192 1,244,959 /1960 France 3 35/278 Primary Examiner-J. V. Truhe Assistant Examiner-Hugh D. Jaeger Attorney-Kinzer, Dorn and Zickert ABSTRACT: A terminal assembly for a tubular solenoid including a terminal cap having a pair of terminals secured thereto with openings therethrough which receive leads from the solenoid coil and may be attached to the terminals. An insulator is provided to coact with metal parts of the solenoid to enable the coil leads to be completely insulated therefrom.

SOLENOID TERMINAL ASSEMBLY This invention relates in general to a solenoid, and more particularly to a tubular solenoid, and still more particularly to a tenninal assembly for a tubular solenoid.

Heretofore, tubular solenoids have been provided with leads extending from the casing, such as illustrated in U.S. Pat. No. 3,303,455. Because of the different installations in which a solenoid may be used, it has been necessary to provide several models differing only in the length of the leads which provide power to the coil of the solenoid Accordingly, it is necessary for the manufacturer to stock and designate several different models only because of the lead length requirements, and similarly a user must stock several models as spare parts.

The present invention resides in eliminating the above difficulty in providing a terminal assembly for tubular solenoids having a pair of terminals connected to the coil and to which power to the solenoid can be provided. Installation thereafter of the solenoid in a device only requires soldering or attaching of suitable leads or lead assemblies to the terminals. Lead length may easily be fashioned to a desired size on the job. Accordingly, the necessity of stocking and ordering several models of the same solenoid with different lead lengths or different lead assemblies is eliminated.

The tenninal assembly of the present invention includes a terminal cap attachable to the end of the solenoid opposite the plunger end. A pair of terminals are mounted on the terminal cap in any suitable manner, and connected to the opposite ends of the coil of the solenoid through lead holes or channels provided therein and in the solenoid body which are completely insulated from the metal parts. The need for internal wiring is eliminated. The terminals may thereafter have leads attached thereto, or lead assemblies such as quick disconnect couplings attached thereto.

It is therefore an object of the present invention to provide a new and improved terminal assembly for tubular solenoids, which can be inexpensively manufactured and assembled, and which includes a minimum number of parts, and which eliminates the need for internal wiring and the need for providing several solenoid models differing only in the lead lengths or lead assemblies.

It is a further object of this invention to provide a terminal assembly for tubular solenoids that can be made and assembled at less cost than any other known terminal assembly.

Other objects, features and advantages of the invention will be apparent from the following detailed disclosure, taken in conjunction with the accompanying sheets of drawings, wherein like reference numerals refer to like parts, in which:

FIG. 1 is an axial sectional view taken through a solenoid having the terminal assembly of the present invention;

FIG. 2 is an exploded perspective view of the terminal assembly;

FIG. 3 is an elevational view of one end of the terminal cap of one form of the present invention;

FIG. 4 is an end view of the other end of the terminal cap;

FIG. 5 is a sectional view taken through a terminal cap as sembly according to the invention and illustrating a modified means for preventing relative rotation between the cap and plug;

FIG. 6 is a sectional view taken along the line 6-6 of FIG.

FIG. 7 is an exploded perspective view of a modified means for preventing relative rotation between the cap and plug; and

FIG. 8 is a fragmentary sectional view of the plug and showing the cap in phantom modified to illustrate another means for assembling the cap and plug.

Referring now to the drawings, and particularly to FIG. 1, the tubular solenoid includes generally a coil tube 10 of nonmagnetic material, a plug 11 of magnetic material and secured to one end of the coil tube, a faceplate 12 of magnetic material and secured at the other end of the coil tube, a plunger 13 of magnetic material slidably received within the coil tube 10, a coil 14 arranged over the coil tube and between the plug and face plate, and a cover or casing 15 over the coil and fastened in place by staking same to the face plate at 16. A nonmagnetic seating ring 17 is provided on the outer end of the plunger for seating the plunger in energized position so that the inner conical end is in slightly spaced relation from the conical recess of the plunger 11 to reduce residual magnetism between the plunger and plug. A nut 18 is received on the face plate to facilitate mounting of the solenoid on a panel 19.

The plug and faceplate include radial flanges 20 and 21 respectively which coact with the coil tube 10 to define a bobbin on which the coil 14 may be wound. Insulating tape 22 is provided on the coil tube to insulate the magnet wire of the coil from the coil tube. Similarly, a washer 23 of insulating material is provided at the faceplate to insulate the magnet wire from the faceplate. Insulating tape 24 is provided covering the magnet wire of the coil to insulate it from the cover 15.

The terminal assembly of the invention includes a terminal cap 27, an insulator 28, and the plug 11, the latter being specially formed to coact with the terminal cap and insulator to define the terminal assembly. Terminal plug 11 includes a cylindrical portion 29 extending toward the plunger, the free end of which is formed with a conical recess to mate with the conical end of the plunger.

Magnet wire coil lead holes 30 are provided in the flange 20 of the plug 11 through which the leads of the coil may extend when taken to the terminal cap 27. While the lead holes 30 are shown as extending through the flange in diametrically opposite positions and outside the cylindrical portion 29, it may be appreciated that lead holes may be arranged in side-by-side relation if so desired. The insulator 28 serves to insulate the magnet wire of the coil from the plug, and particularly from the plug flange surface 20a, and in this respect it includes a washer portion 31 having a central hole 32 for accommodating the coil tube of the solenoid. Thus, the insulator can be positioned directly against the surface 204 of the plug flange 20.

In order to insulate the coil leads from the metal plug as the leads extend through the lead holes 30, insulating sleeves 33 extending from the washer portion 31 and making up a part of the insulator 20 are provided which matingly fit within the lead holes of the plug in a manner particularly shown in FIG. 1. The insulator 28 therefore includes the washer portion 31 and the sleeves 33 as a single unit, and it can be appreciated that this may be of any suitable insulating material.

A terminal cap fastening and support extension or stud 34 extends from the plug flange 20 and from the opposite side of the cylindrical portion 29, axially of the plug, and for fitting freely within the stud hole 35 formed axially of the terminal cap 27. The free end of the stud 34 is formed so that it may be rolled over the end of the terminal cap in a recess 36 thereby fastening the terminal cap to the plug and the end of the solenoid. The recess 36 permits the rolled end of the stud to be below the outer surface of the cap. The terminal cap is cylindrical in shape and having the same diameter as the solenoid whereby the external surface serves as a continuation of the surface of the cover 15.

A pair of sockets 37 are formed in the end of the terminal cap adapted to face the plug 11 at diametrically opposite locations in alignment with extension portions 30a of the insulator sleeves 30, as shown in FIG. 1, thereby locking the terminal cap 27 against rotation relative to the plug. Thus, the sockets are arranged so that they will mate with the sleeve extensions when the cap is placed on the supporting stud 34. Lead holes 38 extend through the terminal cap to the outer end and are in alignment with the sockets 37 so that the coil leads 14a can extend through the plug 11 and then through the terminal cap to the exterior end of the terminal cap. A pair of terminals 39 are suitably attached to the outer end of the terminal cap, and to which the coil leads may be soldered or crimped, so that thereafter power connections to the terminals can supply power to the solenoid. It should be appreciated that the terminals may thereafter have leads or lead assemblies attached thereto. For example leads could be soldered to the terminals, or a quick disconnect-type connector could be applied to the terminals.

The terminal cap is made of a suitable electrical insulating material, and is preferably molded of high-temperature, highimpact plastic. The terminals 39 are preferably insert molded in the cap so that they are firmly anchored. The outer end of the tenninal cap is provided with recesses 40, FIG. 4, that are dimensioned to embrace the outlet ends of the lead holes 38 and the terminals 39, so that the coil leads 140 can be brought out of the lead holes 38, twisted around the base of the terminals 39 and soldered or crirnped thereon, thereby keeping the coil leads below the outer end surface 41 of the terminal cap. It should be appreciated that the terminals, while shown as being insert molded, could otherwise be anchored to the cap.

An alternative construction for providing means to prevent relative rotation between the terminal cap and plug is illustrated in FIGS. 5 and 6, wherein the sleeves 33 of the insulator 28 terminate flush with the outer surface of the plug flange 20. A flatted surface 45 is provided on the fastening and supporting stud 34, and a mating flatted surface 46 is provided in the hole 35 of the terminal cap 27. The flatted surfaces on the stud and terminal cap align the lead holes and prevent relative rotation between the cap and plug. it should be appreciated that other means may be provided to prevent the relative rotation between the plug and cap.

A further alternative construction for defining means to prevent relative rotation between the terminal cap and plug is illustrated in FIG. 7, wherein a pin 50 is molded integrally with the terminal cap to mate with a socket 51 formed in the plug, it being appreciated that the location of the pin and socket will effect alignment of the lead holes 38 of the cap with the holes in the sleeves 33 of the insulator 28. It should be further appreciated that the pin 50 may be formed on the plug 11, while the socket 51 could be formed on the cap 27, but since the plug is made of metal and the cap is molded of plastic, it is more economical to place the pin on the cap. In this embodiment, the sleeves 33 of the insulator will terminate flush with the outer surface of the plug 1 1.

Another method of attaching the terminal cap 27 to the plug 11 is illustrated in FIG. 8, wherein the terminal plug 11 is fitted with an axial hole 54 at its outer face instead of having a fastening stud as shown in the embodiment of FIG. 1. A pin 55 having a head 56 is then press-fit into the hole 54 to thereby anchor the cap to the plug. The head of the pin fits in the recess formed in the outer end of the cap.

lt will be understood that modifications and variations may be effected without departing from the scope of the novel concepts of the present invention but it is understood that this application is to be limited only by the scope of the appended claims.

1. In a tubular solenoid having a coil tube in the form of a cylindrical sleeve, a plug of magnetic material secured at one end of said coil tube and having a flange defining with said coil tube one end of a coil bobbin onto which magnet wire may be wound to define a coil, a terminal assembly comprising a terminal cap of insulating material adjacent said plug, a pair of terminals carried by the cap, a pair of wire holes extending through said plug and through which the opposite ends of the coil may pass, means for insulating the magnet wire of the coil from the plug flange, means for insulating the opposite ends of the coil passing through the plug wire holes from the plug, wire holes in said terminal cap mating with the wire holes of the plug, and means securing the cap to the plug, whereby the ends of the coil pass through the wire holes of the plug and cap to be connected to the terminals.

2. The combination as defined in claim 1, wherein said means securing the cap to the plug includes a stud extending from said plug and through a stud hole in said cap and the outer end of the stud is rolled over the cap at the outer side thereof.

3. The combination as defined in claim 2, and means for preventing relative rotation between the plug and cap.

4. The combination as defined in claim 3, wherein the means insulating the magnet wire of the coil from the plug flange and the means for insulatin the o posite ends of the coil passing through the plugholesfirom t e plug includes an insulator having a washer portion and sleeves extending therefrom adapted to fit in the plugholes.

5. The combination as defined in claim 3, wherein said means for preventing relative rotation between the cap and plug includes a pin on the cap or plug mating with a pinhole on the plug or cap.

6. The combination as defined in claim 1, wherein said means securing the cap to the plug includes a hole in said plug, an opening extending through said cap and aligned with said hole, and a headed pin extending through the cap opening and being press fit in said plughole.

7. In a tubular solenoid having a coil tube in the form of a cylindrical sleeve, a plug of magnetic material secured at one end of said coil tube and having a flange defining with said coil tube one end of a coil bobbin onto which magnet wire may be would to define a coil, a terminal assembly comprising a terminal cap of insulating material adjacent said plug, a pair of terminals carried by the cap, a pair of wire holes extending through said plug and through which the opposite ends of the coil may pass, an insulator including a disc portion on the coil side of said plug flange to insulate the magnet wire of the coil therefrom and a pair of sleeves extending through said plug wire holes to insulate the opposite ends of the coil passing therethrough from the plug, wire holes in said terminal cap mating with the wire holes of the plug and the sleeves of said insulator, and means securing the cap to said plug, whereby the ends of the coil pass through the sleeves and cap wire holes to be connected to said terminals.

8. The combination as defined in claim 7, and means for preventing relative rotation between the plug and cap.

9. The combination as defined in claim 8, wherein said means for preventing rotation includes sockets formed in the cap at the inlet ends of the lead holes, and extensions on the sleeves extending into the socket.

10. The combination as defined in claim 8, wherein said means for preventing rotation includes a pin on the cap or plug mating with a pinhole on the plug or cap.

11. The combination as defined in claim 7, wherein said means securing the cap to the plug includes a stud extending from and integral with said plug, and a stud hole in said cap receiving said stud and the outer end of the stud being rolled over the cap at the outer side thereof.

12. The combination as defined in claim 11, and means on the stud and cap stud hole coacting to prevent relative rotation between the plug and cap.

13. The combination as defined in claim 7, wherein said means securing the cap to the plug includes a hole in said plug, an opening extending through said cap and aligned with said hole, and a headed pin extending through the cap opening and being press-fit in said plug hole.

14. The combination as defined in claim 13, and means on the stud and cap stud hole coacting to prevent relative rotation between the plug and cap.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent NO 3 609 610 Dated September 28 1971 Inventor(s) Robert Flentge It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

Column 1, line 8, "No. 3,303,455" should read No. 3,303,445 u v Signed and sealed this 29th day of August 1972.

(SEAL) Attest:

EDWARD M .FLETCHER,JR.

ROBERT GOTTSCHALK Attesting Officer Commissioner of Patents "ORM FO-IOSO (IO-69) USCOMM-DC GOS'IG-PBQ b u s, GcvEmmENT PRINTING OFFICE I969 o36s3n. 

1. In a tubular solenoid having a coil tube in the form of a cylindrical sleeve, a plug of magnetic material secured at one end of said coil tube and having a flange defining with said coil tube one end of a coil bobbin onto which magnet wire may be wound to define a coil, a terminal assembly comprising a terminal cap of insulating material adjacent said plug, a pair of terminals carried by the cap, a pair of wire holes extending through said plug and through which the opposite ends of the coil may pass, means for insulating the magnet wire of the coil from the plug flange, means for insulating the opposite ends of the coil passing through the plug wire holes from the plug, wire holes in said terminal cap mating with the wire holes of the plug, and means securing the cap to the plug, whereby the ends of the coil pass through the wire holes of the plug and cap to be connected to the terminals.
 2. The combination as defined in claim 1, wherein said means securing the cap to the plug includes a stud extending from said plug and through a stud hole in said cap and the outer end of the stud is rolled over the cap at the outer side thereof.
 3. The combination as defined in claim 2, and means for preventing relative rotation between the plug and cap.
 4. The combination as defined in claim 3, wherein the means insulating the magnet wire of the coil from the plug flange and the means for insulating the opposite ends of the coil passing through the plugholes from the plug includes an insulator having a washer portion and sleeves extending therefrom adapted to fit in the plugholes.
 5. The combination as defined in claim 3, wherein said means for preventing relative rotation between the cap and plug includes a pin on the cap or plug mating with a pinhole on the plug or cap.
 6. The combination as defined in claim 1, wherein said means securing the cap to the plug includes a hole in said plug, an opening extending through said cap and aligned with said hole, and a headed pin extending through the cap opening and being press fit in said plughole.
 7. In a tubular solenoid having a coil tube in the form of a cylindrical sleeve, a plug of magnetic material secured at one end of said coil tube and having a flange defining with said coil tube one end of a coil bobbin onto which magnet wire may be wound to define a coil, a terminal assembly comprising a terminal cap of insulating material adjacent said plug, a pair of terminals carried by the cap, a pair of wire holes extending through said plug and through which the opposite ends of the coil may pass, an insulator including a disc portion on the coil side of said plug flange to insulate the magnet wire of the coil therefrom and a pair of sleeves extending through said plug wire holes to insulate the opposite ends of the coil passing therethrough from the plug, wire holes in said terminal cap mating with the wire holes of the plug and the sleeves of said insulator, and means securing the cap to said plug, whereby the ends of the coil pass through the sleeves and cap wire holes to be connected to said terminals.
 8. The combination as defined in claim 7, and means for preventing relative rotation between the plug and cap.
 9. The combination as defined in claim 8, wherein said means for preventing rotation includes sockets formed in the cap at the inlet ends of the lead holes, and extensions on the sleeves extending into the socket.
 10. The combination as defined in claim 8, wherein said means for preventing rotation includes a pin on the cap or plug mating with a pinhole on the plug or cap.
 11. The combination as defined in claim 7, wherein said means securing the cap to the plug includes a stud extending from and integral with said plug, and a stud hole in said cap receiving saiD stud and the outer end of the stud being rolled over the cap at the outer side thereof.
 12. The combination as defined in claim 11, and means on the stud and cap stud hole coacting to prevent relative rotation between the plug and cap.
 13. The combination as defined in claim 7, wherein said means securing the cap to the plug includes a hole in said plug, an opening extending through said cap and aligned with said hole, and a headed pin extending through the cap opening and being press-fit in said plug hole.
 14. The combination as defined in claim 13, and means on the stud and cap stud hole coacting to prevent relative rotation between the plug and cap. 